Rubber insulated power cable



July 3, 1951 s. BUNlsH ETA. 2,558,929

RUBBER INSULATED POWER CABLE Filed April 11,V 1947 'Er-5- E Patented July 3, 1951 l stephen Bunish and Herbert 0.wmnm, Marlen, Ind., assignors to Anaconda Wire and Cable Company, a corporation-o! Delaware- Application Apni 11,1947, semi No. 740,932

1o claims. f (ci. 174-116) 1 This invention relates to rubber-insulated power cables, and provides an improved cable constructed to provide greater safety when substantially overloaded than cables heretofore known or proposed. While itis generally vinadvisable to overload power cables, it is impossible to" Y avoid doing so in many services,` and consequently cable manufacturers must consider and provide for safe operation of the cable when overloaded for reasonable periods of time. A

The safety with which a cable may carry current overloads depends on the maximum -temperature which the cable insulation attains. during overload operation. The temperature of the insulation is determined not only by the amount of heat generated by the current in the cable conductors, but also by the rate at which thel heat so generated is dissipated. In any appreciable length of cable, the heat must be dissipated by conduction through the insulation.

Good electrical insulators are also, generally-;

containing from 5%v to 20% by weight of graphite. We have found that at -least about 5% by weight of graphite is advisable in. order to secure a substantial increase-'in the thermal conductivity of the rubber composition in which it-is included; and that not more than about 20% of graphite should be employed, in order to avoid impairing "excessively the dielectric properties of the composition, and also to avoid making the composition too dry to be extruded readily in the course of manufacturing the cable.

Power cables thus constructed, using graphitecontaining'rubber, may carry overload currents safely for a longer period of time than such heretofore known cables. The thermal conductivity of the graphite-bearing rubber composition is suicient to' permit substantial overload currents to be carried for a substantial length of time f without causing the temperature of the cable in- 20j.l y Y y v `)h eatfdeveloped inthe conductor is transmitted speaking, good heat insulators, and consequently the electrical insulation on a power cable interferes with rapid conduction of heat from the conductor and its dissipation to the atmosphere'.

A typical multi-conductor rubber-insulated power cable as heretofore made comprisesA two or more rubber-insulated conductors side :by side,r

sulation to, rise beyond its safe limit, because the more -rapidly to the surface of the .cable and thence dissipated to the atmosphere.

' 'jWe have' found, -in addition to the foregoing,

' that the character of the filler employed in makingup'the rubber composition has a substantial effect on its thermal conductivity. 1 Carbon black is a particularlydesirable filler,v from this standwith jute or other fibrous fillers laid in the interstices between the conductors, and witha 'rubber'.

jacket enclosing the assembly. Sometimes 'l an inner fibrous jacket surroundingthe conductors and fillers inside the outer protective-jacketfalso 'Y is included in the structure. We have found 'that the fillers (and inner jacket when employed); Aconf-4mV tribute largely to limiting the ratev of heat conduction from the conductors to the outer surface of the cable. We have also found that a rubber, ,i

point, tor use `in conjunction with the graphite. 'Zinc oxide land clay are also satisfactory fillers. On .the other hand, Whiting (finely divided cal- A'cimn carbonate) is not such a good filler to employ. Whatever -the filler, however, the thermal v,conductivity ofthe composition is improved by composition containing a substantialamountfofi graphite possesses good thermal conductivity, 'as

compared with the materials heretofore employed as fillers and elsewhere in the insulation of power vl,tliefaddition of graphite in an amount between 5 \%vand 20% byv weight, as compared with the thermal conductivity of the same composition vwithout the'graphite. A

f j- The invention particularly contemplates multifm? conductor cables in which the interstices between they conductors are filled with a rubber composition of the character described. Howcables; and that this material maybe used in. y making components of the cable insulation with the result that the transfer of heat from the conductor through the insulation is substantially Aincreased. We have discovered that an amount l.of graphite effective for this purpose may still be low enough so as not to impair significantly the delectric qualities ofthe rubber insulation. v,

Based on these discoveries, our invention provides an improved rubber-insulated power cable, characterized in that at least a substantial part of the rubber insulation well beneath the outer surface layer is composed of a rubber composition ever, the invention is not limited to this particularvr feature.. Single-conductor. rubber-cov- Y ered cables, having a substantial'part of the'insulation well beneath the surface layer thereof A-composed of graphite-bearing rubber as herein described, are advantageous. Other parts of a multi-conductor cablel than thefiller in the interstices between conductors `may with advantage be made with graphite-containing rubber.

vTwo embodiments of the invention, as applied to a three-conductor rubber-insulated cable and as applied to a single conductor power cable, are described in greater detail below in position 1, which contains graphite and posses-k ses good thermal conductivity, is extruded about the three conductors so as to lill the interstices between the conductors and impart a circularcross section to the structure. A webbing of fibrous strands 8 may be applied over the composition 1 to provide increased mechanical strength against tearing 'of the composition, particularly' in the regions Where it is thin, under radially outward forces. The webbing 8 should be of open mesh construction so as to interfere as little as possible with transfer of heat radially through the insulation. An outer rubber jacket 8 is extruded over the webbing to complete the the cable, and so enables the cable to carry a greater current than has heretofore been possible without causing the temperature of the conducvalue.

Figs. 3 and 4 show a cable generally similar to that shown in Figs. 1 and 2, but having only a' tor (and of the insulation) to rise beyond a safef cable is completed by a protective outer covering I3 of a rubber composition.

In the cable construction shown in Figs. 3 and f 4, the intermediate layer I2 of graphite-contain-I have maximum dielectric strength, while the cable as a whole is enclosed in a protective outer rubber covering speciiically compounded to provide maximum mechanical protection.

Typical rubber compositions of improved thermal conductivity that may be employed in accordance with the invention are given in the following examples:

Example I Ingredient Pevltby Rubber Stock 35. 0 Stabilizer (e. g., Altax) 0.25 Mineral Rubber (Plsticizer) 5.00 Carbon Black l0. 00 Light Oil (Plasticizer).--. 3. 00 'd 1.0() 10.00 30. 5.00

The Altax stabilizer referred to in the above example is defined in the Vanderbilt Rubber Handbook, 8th edition, published 1942, as a commercially pure benzothiazyl disulde, which is prepared by oxidizing commercially pure mercaptobenzo thiazole.

Eampze 11 Ingredient Povigtby Rubber Stock 3X. 00 Stearic Acid u. 50 Stabilizer 1. 25 Oily Plasticizer. 2, 00 Calcined Magnes i. 50 Carbon Black 44. 25 Graphite l0. 00 Zinc Oxide 2. 50

Example III Ingredient Peivteiglitby Rubber stock. 38. 00 Stearic Acid. 0. 50 Stabilizcr.... 1. 25 Oily Plasticizer.. 2.00 Calcined Magnesia. 1. 50 Carbon Black 34. 25 Graphite... 20. 00 Zinc Oxide. 2. 50

' are of course incorporated in the composition in the customary small amounts.

Of the above three exemplary compositions, the second is generally the most satisfactory, because its thermal conductivity is somewhat better than the rst, and its suitability for extrusion in cable manufacture is better than the third. The improved thermal conductivity of the composition of Example l1, as compared with that of Example I, results from the elimination of mineral rubber and reduction in the amount of oily plasticizer, both of which we have found tend to decrease the thermal conductivity of rubber compositions. Further, the clay employed in the composition of Example I is not quite so good a tlller from the standpoint of thermal conductivity of the composition as is the carbon black employed in Examples II and III.

'I'he composition of Example III possesses better thermal conductivity than does the composi tion of Example II, owing to the increased percentage of graphite. However, 20% by weight of graphite is about the upper limit on the amount of this ingredient that may be employed without rendering the composition too dry and stiff for extrusion during manufacture of the cable. In addition, 20% by weight of graphite is about the maximum that can be employed without decreasing the electrical resistivity of the composition too much-for it to serve effectively as an insulator. It is chiefly because the, graphite in Example DI is at about the upper limit range that this composition is generally not so much preferred as the composition of Example II, containing a somewhat smaller, but yet effective, amount of graphite.

'I'he thermal conductivities of the foregoing rubber compositions have been measured in the following manner: A circular disc of the rubber composition, 3A of an inch thick by 6 inches in diameter, at a temperature of 77F., is placed on a controlled-temperature hot plate, the surface of which is maintained at 280 F. The time required for the upper surface'of the disc, at its midpoint, to reach 160 F., is measured. Using this test, a sample made from a composition according to Example l, in which' neoprene gum stock was employed as the rubber stock, required 25 minutes for its upper surface to reach 160 F. (Neoprene is a polymerized chloroprene product.) Another sample, made according to Example II, again using neoprene gum stock, required 18 minutes for its upper surface to reach 160 F. A third sample prepared according to Example III, again using "neoprene gum stock, required about 15 minutes for its upper surface to reach 160 F. Y

'I'he electrical resistivity of the rubber compositions made according to Examples I and 1I were amply high for power cable insulation purposes, being over 2 l0s ohms per cubic centimeter. The rubber composition according to Example Il'I had a resistivity at 75 F. of 4X 10 ohms per cubic centimeter. Greater amounts of graphite than 20% by weight decrease the electrical resistivity still further.

While the foregoing data relates particularly to samples compounded with neoprene gum stock, other rubbertgum stocks may also be used in making up the rubber composition, both synthetic gum stocks-such as Buna (GRS) rubber gum (a copolymer of butadiene and styrene) and butyl rubber gum (a copolymer of butadiene and isoprene)-and natural rubber gum stock. The thermal conductivity of the rubber composition is affected somewhat by the gum stock chosen, as some gumv stocks possess better thermall conductivity than others. The

Aof its v amount of variation caused by using 'different gum stocks, however, is not large, and ordinarily the choice of gum stock will not depend on its. i effect on the thermal conductivity of the comv the composition, as compared with a similar comthe primary insulation for cables destined for ordinary low-voltage power service (i. e., for services where the maximum potential across the insulation is of the order of 600 volts or less).

It is particularly desirable to construct the cable so that the graphite-containing rubber forms a substantial part of the insulation well below the outer surface of the cable and near (or even in contact with) the conductors, because this is the part of the cable where a maximum rate of heat transfer is desired in order to achieve maximum safety during overload operation.

A cable made substantially as shown in Fig. 1 has been Acompared with a similar cable using the same number and size of conductors but constructed in the conventional fashion with jute fillers in the interstices between the insulated conductors, in place of graphite-containing rubber. The same current which caused the conductor .temperature to reach almost 500 F. in l0 minutes in the conventional cable with jute fillers. caused the conductor temperature to reach a value of less than 400 F. in the `same length of time in the new cable.

The increased safety of the new cable during overload operation results from two factors :l In the first place, the high thermal conductivity of the graphite-containing rubber, by limiting the temperature attained by the insulation during the period of the overload, reduces the extent to which the insulation is injured by thermal decomposition, as compared with heretofore known cables. The rate at which chemical reactions proceed l(including thermal decomposition reactions) approximately doubles with each 10 C.

rise in temperature. Hence the rate at which deterioration of the insulation of the new cable pound, but rather on its other physical properi ties and its availability.'

The thermal conductivity of the composition 11:'

is considerably affected bythe fillers use d in` preparing the compound. Carbon blacks that yield a soft compound, such as the finelydivided softl carbon black obtained by thermal decomll` position, or cracking of natural gas and sold under under the designation P-33," are particularly advantageous from the standpoint of yielding'a compound having good thermal conductivity.

generally possess a somewhat lower thermal conductivity than compounds in which carbon black or zinc oxide is employed; and Whiting is not quite so good even as clay. Regardless of the Y ller employed, however, the inclusion oi graphite in an amount from 5% to 20% by weight substantially enhances the thermal conductivity of occurs during overload operation is reduced by a very large factor, as compared with heretofore known cables that under comparable overload I' Vconditions might become 50 to 100 C. hotter. In the second place, if a short-circuit should occur during overload operation of the cable and the 4insulation should be set are in the vicinity of 'theshort-circuit, the fact that the insulation elsewhere is at a lower temperature than would be the case with heretofore known cables enables While the new cable may be used with some greater safety than previously known cables at current loadings o1' 100% to 150% of rated value.

the benefits of the new cable are most apparent when higher overloads up to 300% or more are applied. Overloads of this magnitude are not uncommon in the operation of mining machinery, where handling of large blocks of the material being mined quite often requires a very large amount of power for a short period of time.

We do not imply, in what has been said above, that operation of the new cable at above its normal current rating (based on the size of the conductors) is generally permissible and safe.

We have merely pointed out that in those services where power cables are unavoidably overloaded from time to time, the new cable provides a substantially greater margin of safety than cables heretofore known.

We claim:

1. Rubber-insulated power cable comprising a plurality of conductors each having a rubber insulating jacket, a filler in the interstices Vbetween the insulated conductors, and a rubber outer covering, the ller being a rubber composition which contains to 20% by weight of graphite, has an electrical resistivity at 75 F. of at least 4 105 ohms per cubic centimeter and possesses suiilciently good thermal conductivity that the midpoint of the upper surface of a layer thereof 6 inches in diameter and three-fourths of an inch thick, originally at a temperature of 77 F., will reach a temperature of 160 F. at least within 25 minutes when the layer is placed on a hotplate maintained at 280 F.

A2. Cable according to claim 1, in which the ller also contains from about 10% to 45% by weight of carbon black in addition to the graphite.

3. Cable according to claim 2, in which the ller contains about 45% by weight of carbon black and about 10% by weight of graphite.

4. Rubber-insulated power cable comprising at least one conductor, an outer insulating jacket, and rubber insulation between the conductorand the outer insulating jacket composed of a. rubber composition which contains from 5% to 20% by weight of graphite, has an electrical resistivityat 75 F. of at least 4 106 ohms per cubic centimeter and possesses sufiiciently good thermal conductivity that the midpoint of the upper surface of a layer thereof 6 inches in diameter and three-fourths of an inch thick, originally at a temperature of 77 F., will reach a temperature of 160 F. at least within 25 minutes when the layer is placed on a hotplate maintained at 230 F.

5. Cable according to claim 4 in which said rubber composition also contains from about 10% to 45%vby weight of carbon black.

4 6. A power cable comprising a plurality of con ductors, fillers in the interstices between the conductors composed of a rubber composition which contains v5% to 20% by weight of graphite, has an electrical resistivity at 75 F. of at least 4x10A ohms per cubic centimeter and possesses suilciently good thermal conductivityA that the midpoint of the upper surface of a layer thereof v6 inches in diameter and three-fourths of an inch thick, originally at a temperature of 77 F., will reach a temperature of 160 F. at least within 8 25 minutes when the layer is placed on va hot' plate maintained at 280 F.

'7. Cable according to claim 6 in which the rubber composition also contains from about 10% to 45% by weight of carbon black 8. Cable according to claim 6 in which the rubber composition contains about 10% by weight ot graphite, and which also contains about 45% by weight of carbon black.

9. A power cable comprising a conductor, a rubber insulating jacket surrounding the conductor, and a layer surrounding the rubber insulating jacket comprising a rubber composition which contains 5% to 20% by weight of graphite, has an electrical resistivity at F. of at least 4x106 ohms per cubic centimeter and possesses suillciently good thermal conductivity that the midpoint of the upper surface of a layer thereof 6 inches in diameter and three-fourths of an inch thick, originally at a temperature of 77 F., will reach a temperature of F. at least Within 25 minutes when the layer is placed on a hotplate maintained at 280 F.l

10. A power cable of the character described comprising a conductor surrounded by an insulating rubber jacket, a layer of rubber` composition surrounding said jacket which contains 5% to 20% by weight of graphite, has an electrical resistivity at 75 F. of at least 4 106 ohms per cubic centimeter and possesses sufficiently good thermal conductivity that the midpoint of the upper surface of a layer thereof 6 inches in diameter and three-fourths of an inch thick, originally at a temperature of 77 F., will reach a temperature of 160 F. at least within 25 minutes when the layer is placed on a hotplate maintained at 280 F., and a protective rubber covering surrounding said layer of graphite-containing rubber.

STEPHEN BUNISH. HERBERT C. WITIHOFF.

REFERENCES CITED `.The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,977,325 Ptannkuch Oct. 16. 1934 2,096,840 Bormann Oct. 26, 1937 2,142,625 Zoethout Jan. 3, 1939 2,234,068 Wiseman Mar. 4, 1941 2,286,826 Morrison June 16, 1942 FOREIGNPATENTS Number Country Date 526,895 England Sept. 27, 1940 OTHER REFERENCES An article, Electrically Conducting Neoprene land Rubber, by Habgood and Waring, found in Rubber Chemistry and Technology," vol. 15:

1942, pp. 14S-157; Mix No. F. 5703" in Table VI on page 153; copy in Div. 65 in 102 (2).

The book Science of Rubber by K. Memmler;

class 174- American ed. by Dunbrook and Morris, `1934;

published by Reinhold Publ. Corp., N. Y.; pp. 463-465; copy in Div. 15 marked TS1890, M42. 

